Thermal Model for Dry Dual Clutch Temperature Estimation
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Solution Overview
Problem
Determining clutch temperatures in dry dual clutch transmissions is challenging due to the difficulty in placing temperature sensors directly on the clutches, which can lead to permanent damage and reduced torque capacity if critical temperatures are exceeded.
Innovation Solution
A thermal modeling method is employed to estimate clutch temperatures by determining heat inputs from each clutch and housing air temperature, using either a five-state or seven-state thermal model to calculate the temperatures of the clutches, center plate, and other components, allowing for control actions to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are placed directly on the clutches to measure temperatures, then temperature measurement accuracy is improved, but the clutches are damaged and torque capacity is reduced due to permanent damage at critical temperatures
Solution Approach 1:
The patent introduces a thermal model as an intermediary between the clutches and temperature sensors. Instead of placing sensors directly on the clutches, the system uses thermal models that calculate clutch temperatures based on heat inputs from clutch operation and heat transfer through the clutch assembly structure. This mediator approach provides accurate temperature estimation without the need for direct contact sensors that would damage the clutch components.
Solution Approach 2:
The patent creates a thermal copy or simulation of the clutch system that replicates temperature behavior without requiring physical sensors on the actual clutches. The thermal model copies the thermal characteristics and heat transfer pathways of the clutch assembly, allowing temperature measurement through calculation rather than direct sensing, thus avoiding damage to the original clutch components.
2Reliability
If direct temperature measurement is used to prevent damage, then reliability is improved, but the complexity of the measurement system increases due to sensor placement difficulties
Solution Approach 1:
The patent replaces the mechanical sensor placement approach with a computational thermal model. Instead of using physical temperature sensors that would require complex installation on the clutch components, the system uses a mathematical model that calculates temperatures based on heat input data and thermal properties of the clutch assembly. This substitution of mechanical measurement with computational analysis reduces system complexity while maintaining reliability.
3Reliability
If thermal modeling is used to estimate clutch temperatures, then the risk of clutch damage is reduced, but the complexity of the thermal model increases when including additional temperature states
Solution Approach 1:
The patent segments the thermal model into different states based on the level of detail required. The model can operate with five temperature states for basic protection or expand to seven temperature states for more comprehensive monitoring. This segmentation allows the system to balance complexity and accuracy by selecting the appropriate model level, providing clutch protection without unnecessarily increasing computational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively estimates clutch temperatures, preventing damage and maintaining torque capacity by accurately determining the operating temperatures of the clutches and center plate, even when direct temperature measurement is impractical.
Implementation Method 1
determining a housing air temperature of housing air within a bell housing case of the dry dual clutch mechanism. A thermal model is applied with the determined first heat input and second heat input. The thermal model includes temperature states for at least the first clutch, the second clutch, and the center plate.
Data Source
AI summary
A method of determining temperatures for a dry dual clutch mechanism includes one or more steps, such as determining a first heat input from a first clutch and determining a second heat input from a second clutch. The second clutch is separated from the first clutch by a center plate. The method also includes determining a housing air temperature of housing air within a bell housing case of the dry dual clutch mechanism. A thermal model is applied with the determined first heat input and second heat input. The thermal model includes temperature states for at least the first clutch, the second clutch, and the center plate. From the thermal model, the method determines at least a first clutch temperature and a second clutch temperature. The method includes executing a control action with the determined first clutch temperature and second clutch temperature.